Method for manufacturing professional grade skateboard decks using recycled wood fiber veneer substrate

ABSTRACT

An environmentally friendly composite material for use in the manufacture of professional grade skateboard decks and other high quality equipment and sporting gear. In the one embodiment, a skateboard deck is manufactured from a composition of recycled hard rock maple wood fibers, a polyvinyl acetate adhesive, a cross-link catalyst and water. The malleable nature of the composite material prior to curing, allows the skateboard deck to attain virtually any desired shape. Differing composites and adhesives may be employed to achieve the a similar product when properly cured. Once cured, the composite material is light weight, strong, durable, and requires no lacquers or other sealers.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to a method for manufacturingskateboard decks, and particularly, to a method for manufacturingprofessional grade skateboard decks using recycled wood fiber veneer assubstrate and further to the deck developed using this method.

2. Description of the Related Art

The skateboarding industry is a multibillion dollar industry comprisedof manufacturers, riders, and numerous media outlets across the UnitedStates and around the world. The skateboard deck, the component uponwhich a user is carried, is obviously an essential component of askateboard. Consequently, the manufacturing process for skateboard decksis a crucial step in the manufacturing of skateboards.

The manufacturing process for skateboard decks is well known, andgenerally comprises a series of steps through which a number of woodveneer layers, in one optimal embodiment seven veneer layers, are gluedand pressed together in a mold to form a uniform skateboard deck. Inmany embodiments, professional grade skateboard decks are manufacturedusing the highest quality hard maple wood, a material known to thoseskilled in the art as “hard rock maple.” In the current state of theart, roughly 20% to 25% of the high quality “hard rock maple” materialis lost during manufacturing, as a result of the removal of excessmaterial, and associated sanding required for smoothing the deck'sedges.

The present invention relates to a novel, environmentally friendlyprocess for manufacturing skateboard decks, wherein said decks aremanufactured using recycled high quality “hard rock maple,” therebyreducing the demand for raw materials, reducing production costs, andimproving a number of desirable deck properties such as durability,flexibility, and improved water resistance.

Although methods for deck manufacturing are widely known, and a numberof variations exist dealing primarily with substitutions of substratefor wood veneer (fiberglass and carbon fiber), no environmentallyfriendly method for manufacturing professional grade skateboard deckspresently exist in the art. Additionally absent are methods or decksutilizing primary raw material comprising recycled high quality “hardrock maple,” to reduce production costs, improve performance, and reducethe environmental impact of manufacturing.

In summary, scrutiny of the foregoing prior art reveals that at present,there exists no environmentally friendly process for the manufacture ofprofessional grade skateboard decks, that utilizes recyclable highquality “hard rock maple” as substrate.

SUMMARY OF THE INVENTION

The instant invention, as described further herein, imparts a novel,environmentally friendly method for manufacturing professional gradeskateboard decks utilizing recycled high quality “hard rock maple” forimproved durability, reduced production costs, and reduced environmentalimpact. The instant invention as illustrated herein, is neitheranticipated, nor rendered obvious or present in any of the prior artmethods, neither alone nor in any combination thereof.

The primary object of the instant invention is to provide a novel rawmaterial for the manufacture of skateboard decks, wherein said rawmaterial consists of recycled high quality “hard rock maple” wood.

Another object of the instant invention is to provide a method for thesynthesis of said novel raw material, wherein said novel raw materialcan be utilized in the manufacture of skateboard decks, as well as anumber of alternate applications such as snowboards, wakeboards, skis,etc.

Another object of the instant invention is to provide a method for thesynthesis of said novel raw material, wherein said synthesis methodmaximizes the efficiency of raw material utilization during manufacture.

Another object of the instant invention is to provide a method for thesynthesis of said novel raw material, wherein said synthesis methodrequires no lacquer, and consequently emits no volatile organiccompounds during manufacture.

Another object of the instant invention is to provide a method for thesynthesis of said novel raw material, wherein the chemical compositioncan be altered to attain different desirable physical properties such asthickness, elasticity, etc.

There has thus been outlined, rather broadly, the more importantfeatures of the method for manufacturing professional grade skateboarddecks utilizing recycled high quality “hard rock maple” in order thatthe detailed description thereof that follows may be better understood,and in order that the present contribution to the art may be betterappreciated. There are additional features of the invention that will bedescribed hereinafter and which will form the subject matter of theclaims appended hereto.

In this respect, before explaining at least one embodiment of theinvention in detail, it is to be understood that the invention is notlimited in its application to the details of construction and to thearrangements of the components set forth in the following description orillustrated in the drawings. The invention is capable of otherembodiments and of being practiced and carried out in various ways.Also, it is to be understood that the phraseology and terminologyemployed herein are for the purpose of the description and should not beregarded as limiting.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the present invention will be apparent from the followingdetailed description of exemplary embodiments thereof, which descriptionshould be considered in conjunction with the accompanying drawings, inwhich:

FIG. 1 illustrates the initial hard maple wood material in an initialphase, prior to the grinding into fiber phase and subsequent to thegrinding into fiber phase;

FIG. 2 illustrates the wood fibers;

FIG. 3 illustrates a mold containing the maple wood fiber;

FIG. 4 illustrates an inferior half of a mold and further illustratesthe maple wood fiber evenly spread throughout the mold;

FIG. 5 illustrates an inferior half of a mold with a polyethylene sheetlaying over the maple wood fiber for processing;

FIG. 6 illustrates a complete mold comprising a superior half andinferior half of the mold;

FIG. 7 illustrates a plurality of molds being concurrently pressed;

FIG. 8 illustrates a plurality of veneers comprising ribbed inserts;

FIG. 9 illustrates a plurality of veneers concurrently being pressed;

FIG. 10 illustrates a plurality of veneers comprising different hues;

FIG. 11 illustrates a plurality of veneers during curing;

FIG. 12 illustrates the entirety of the mold components includingsuperior half, inferior half, side railing, and polyethylene sheet; and,

FIG. 13 illustrates a plurality of skateboard molds.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the Figures, FIG. 1, the starting hard maple wood materialboth before and after grinding into fibers is illustrated. The instantprocess comprises utilization of a grinding machine to grind the hardmaple wood into wood fibers is illustrated and a band saw used to cutstrips of wood to make ribs, is illustrated. Further a belt sander isutilized to smooth the ribs from band saw marks.

FIG. 1 illustrates the hard maple wood material in an initial phase 1,prior to the grinding into fiber phase and subsequent to the grindinginto fiber phase 2. FIG. 2 illustrates a close up view of the woodfibers 2. FIG. 3 illustrates a mold 3 containing the maple wood fiber 2.FIG. 4 illustrates an inferior half of a mold 4 and further illustratesthe maple wood fiber evenly spread throughout the mold 2. FIG. 5illustrates an inferior half of a mold 4 with a polyethylene sheet 5laying over the maple wood fiber for processing. FIG. 6 illustrates acomplete mold comprising a superior 6 and inferior half of the mold 4.FIG. 7 illustrates a plurality of molds 3 being concurrently pressed.

Additionally FIG. 8 illustrates a plurality of veneers 7 comprisingribbed inserts 8. FIG. 9 illustrates a plurality of veneers 7concurrently being pressed and FIG. 10 illustrates a plurality ofveneers 7 comprising different hues. FIG. 11 illustrates a plurality ofveneers 7 during curing. FIG. 12 illustrates the entirety of the moldcomponents including superior half 6, inferior half 4, side railing 9,and polyethylene sheet 5. Finally, FIG. 13 illustrates a plurality ofskateboard molds 10.

In one embodiment, a material composition for the manufacture ofskateboards and other sporting equipment such as snowboards orwakeboards may comprise a range of thirty percent to fifty percent byweight of polyvinyl acetate adhesive, a range of one percent to fivepercent by weight of liquid cross-link catalyst, a range of thirtypercent to fifty percent by weight of recycled hard rock maple woodfibers, a range of fifteen percent to twenty percent by weight of water.

In the case of a skateboard deck, where the desired application is thatof a 9.5 inch (24.1 centimeter)×35 inch (88.9 centimeter) veneer, themanufacture process consists of two stages. In the first stage of saidprocess, 5.6 ounces (158.75 grams) of hard maple wood fibers areweighed. Said fibers are evenly spread onto a 9.5 inch (24.1 centimeter)×35 inch (88.9 centimeter) mold. Said mold is oscillated in order toattain optimal spread of the fibers, and a Polyvinyl Chloride tube isapplied in order to level the fibers evenly throughout the mold.

Once the fibers are evenly distrusted along the mold, the edges of apre-waxed polyethylene sheet measuring 9.5 inch (24.1 centimeter)×35inch (88.9 centimeter) are rounded off, and said polyethylene sheet isran through a FIN glue machine, which applies an adhesive layer ofapproximately 16 mil., onto the superior side (hereinafter glue side) ofsaid polyethylene sheet. Immediately upon exiting the FIN glue machine,the Polyethylene sheet is placed glue side down in direct contact withthe hard maple wood fibers. The superior half of the mold is placeddirectly over the inferior half of the mold, and the complete mold isplaced under thirty tons of pressure for a period of twenty to thirtyminutes. If a ribbed finish is desired, a putty knife is use to abrasethe surface of the veneer after ten to fifteen minutes of curing.

After said pressing period, the mold is opened with the polyethylenesheet facing down, placed on a rack fiber side up, and allowed to curefor a period of forty eight hours. During the second stage of theprocess the veneer is placed on a clean surface glue side down. A fiberglass laminating tool is used to create abrasions in the substratesurface or abrase the substrate surface, in order to attain improvedwood absorption. Thirty two ounces (0.946 Liters) of polyvinyl acetateadhesive are mixed with fourteen ounces (0.414 Liters) of warm water,allowing said mixture to settle from ten to twenty minutes in order todissipate any air bubbles. After said settling period is complete, saidmixture is sprayed onto the abrased surface of the veneer. This processis repeated from four to five times, allowing the veneer to absorb saidmixture in between applications. The veneer is then allowed to cure fromten to fifteen minutes.

The veneer is then placed on a polyethylene sheet and introduced into aheat tunnel whose temperature can range from 110° Fahrenheit (43.3°Celsius) to 120° Fahrenheit (48.9° Celsius), allowing the surface glueto begin the drying process. Upon exiting the heat tunnel, two beads ofglue are placed along the perimeter of the veneer, wherein said bead areplaced approximately half an inch apart. The veneer is then placed glueside down onto an additional 9.5 inch (24.1 centimeter)×35 inch (88.9centimeter) sheet of polyethylene plastic and a sharpened roller dockeris applied onto the dried glued side of said veneer, wherein said rollerperforates the veneer sequentially every quarter inch. An additional 9.5inch (24.1 centimeter)×35 inch (88.9 centimeter) of polyethylene isplaced on said veneer, such that polyethylene sheets are placed indirect contact with both superior and inferior surfaces of a singleveneer. If a plurality of veneers are desired, a polyethylene sheet, aveneer, and a polyethylene sheet can be placed on top of another suchthat the number of veneers present will be one unit lower than thenumber of polyethylene sheets.

Once the desired number of veneers has been properly arranged, a rail isplaced along the perimeter, veneers are placed on a press and areapplied sufficient pressure to cause the beads of un-watered down glueto exit the veneer, while sealing the edges of said veneer, said processis completed within roughly one hour. Once sealing is attained the railsare removed, and the veneers are pressed for a period spanningapproximately thirty six hours. Upon completion of said period, theveneers are removed from said press and allowed to cure for a periodspanning approximately twenty four hours, upon completion of which thepolyethylene is removed from the first glue side and then second glueside glue once second glue side has dried, the veneer is then allowed tocure from one to two weeks prior to making the recycled skateboarddecks.

1. A material composition for planar objects comprising: a range ofthirty percent to fifty percent by weight of polyvinyl acetate adhesive;a range of one percent to five percent by weight of liquid cross-linkcatalyst; a range of thirty percent to fifty percent by weight ofrecycled hard rock maple wood fibers; and a range of fifteen percent totwenty percent by weight of water.
 2. A skateboard deck comprising: afirst structural layer comprising recycled wood; a second structurallayer comprising of an adhesive; a bonding layer for permanentlyattaching said first structural layer to said second structural layer;and a mounting means disposed to receive two or more trucks.
 3. Theskateboard deck of claim 2, wherein said skateboard is from 7.5 to 8.5inches in width.
 4. The skateboard deck of claim 2, wherein saidskateboard is from 31 inches (78.74 centimeters) to 34 inches (86.36centimeters) in length.
 5. The skateboard of claim 3, wherein saidskateboard is from 4.0 inches (10.16 centimeters) to 4.2 inches (10.67centimeters) in thickness.
 6. The skateboard of claim 4, wherein saidskateboard is from 2.8 lbs. (1.27 kilograms) to 3.2 lbs. (1.45kilograms) in weight.
 7. The skateboard deck of claim 2 wherein saidbonding layer further comprises polyethylene.
 8. The skateboard deck ofclaim 2, wherein said recycled wood is selected from the groupconsisting of maple wood fibers, recycled maple wood fibers, hard rockmaple wood fibers, recycled hard rock maple wood fibers, maple wooddust, recycled maple wood dust, hard rock maple wood dust, and recycledhard rock maple wood dust.
 9. The skateboard deck of claim 2, whereinsaid adhesive is a polyvinyl acetate.
 10. The skateboard deck of claim2, wherein said deck is from 10 centimeters to 45 centimeters in width.11. The skateboard deck of claim 2, wherein said deck is from sixtycentimeters to one hundred centimeters in length.
 12. The skateboarddeck of claim 2, wherein said deck is from six to fifteen millimeters inthickness.
 13. The skateboard deck of claim 2, wherein said deck is fromone to two kilograms in weight.
 14. A method of manufacturing skateboarddecks comprising the steps of: fabricating a mold; placing recycled woodfibers onto mold; placing a polyvinyl acetate adhesive onto the inferiorside of a polyethylene sheet; placing said inferior side of saidpolyethylene sheet directly onto said wood fibers; applying pressure tothe mold to form a veneer; curing said veneer from 35 to 60 hours;abrasing said veneer surface; applying 4 to 5 layers of polyvinylacetate adhesive onto veneer surface; running said veneer through heatmachine; making perforations on veneer with a roller; enclosing theveneer between 2 polyethylene sheets; placing the veneer onto a moldunder pressure; and curing said veneer from 1 to 2 weeks.
 15. The methodof claim 14, wherein a die is applied to render the resulting veneercolored.
 16. The method of claim 14, wherein the veneer is curedutilizing a radio frequency.